Checking Crossover Levers
NOTE: When checking crossover levers with an effective Serial Number 03Z41824-UP, use 145-1853 Calibration Fixture instead of the 5P6602 Adapter.
NOTE: The crossover levers normally do not need checking unless one or more of the following conditions exist (after the timing is checked and the other corrections shown in Troubleshooting have been made):
A. The engine produces too much black smoke.
B. The engine runs rough because fuel delivery is not even.
C. Some cylinders continue to fire at fuel shutoff position.
D. The complete injection group is being reconditioned.
Removal Of Covers
(1) Shutoff solenoid. (2) Top cover.
1. Remove the fuel shutoff solenoid (1), top cover (2) of the fuel injection pump housing and the cover over the torque control group.
2. Remove the fuel that is in the fuel injection pump housing and the governor housing.
Installing Calibration Pin
(3) 3P1546 Calibration Pin (with 15.9410 on it).
3. Put the 3P1546 Calibration Pin (3) in calibration hole as shown.
Installing 5P6602 Adapter Or The 145-1853 Calibration Fixture And 8S7271 Screw
(4) 8S7271 Screw. (5) 5P6602 Adapter or the 145-1853 Calibration Fixture.
4. Install the 5P6602 Adapter (5) or the 145-1853 Calibration Fixture. Fasten it in position with the original bolts.
5. Put the 8S7271 Screw (4) (setscrew) in the hole over the 3P1546 Calibration Pin (3). Tighten the 8S7271 Screw (4) to 2.3 to 2.8 N·m (20 to 25 lb in) with the 2P8264 Socket.
Adjustment Of Low Idle Screw
(6) Low idle screw. (7) Lever.
6. Adjust low idle screw (6) to position lever (7) to 8.9 ± 1.0 mm (.35 ± .04 in) from governor housing boss.
Crossover Levers
(8) Crossover lever. (9) Crossover lever. (10) Dowel pin. (A) Sleeve levers.
7. Loosen the bolts that hold sleeve levers (A) and slide sleeve levers (A) out of the way.
Installing 5P4209 Gauge
(11) 5P4209 Gauge. (12) Shaft. (13) Shaft.
8. Put 5P4209 Gauge (11) on shafts (12) and (13). Slide 5P4209 Gauge (11) toward crossover levers (8) and (9) until dowel pin (10) goes into hole in 5P4209 Gauge (11).
9. If dowel pin (10) must be lifted to go into the hole in 5P4209 Gauge (11), the levers must be adjusted. See Adjustment Of Crossover Levers.
10. If 5P4209 Gauge (11) must be lifted more than 0.20 mm (.008 in) to let dowel pin (10) go into the hole in 5P4209 Gauge (11), see Adjustment Of Crossover Levers.
Checking Clearance Of Crossover Lever
(11) 5P4209 Gauge. (14) Feeler gauge.
11. To check the maximum clearance of 0.20 mm (.008 in) that is acceptable under one side of 5P4209 Gauge (11), hold the center and one side of 5P4209 Gauge (11) against sleeve lever shaft (13). Use feeler gauge (14) to check clearance.
NOTE: After the checking of the crossover levers is complete, the two fuel injection pumps must be calibrated where sleeve levers have been moved to install 5P4209 Gauge. See Fuel Injection Pump Calibration.
Adjustment Of Crossover Levers
1. Remove the fuel shutoff solenoid (1) top cover (2) of the fuel injection pump housing and the cover over the torque control group.
2. Remove the fuel that is in the fuel injection pump housing and the governor housing.
3. Put the 3P1546 Calibration Pin (3) in calibration hole.
4. Install the 5P6602 Adapter (5) or the 145-1853 Calibration Fixture. Fasten it in position with original bolts.
5. Put the 8S7271 Screw (4) in the hole over the 3P1546 Calibration Pin (3). Tighten the 8S7271 Screw (4) to 2.3 to 2.8 N·m (20 to 25 lb in) with the 2P8264 Socket.
6. Adjust low idle screw (6) to position lever (7) to 8.9 ± 1.0 mm (.35 ± .04 in) from governor housing boss.
Crossover Levers
(8) Crossover lever. (9) Crossover lever. (10) Dowel pin. (A) Sleeve levers.
7. Loosen the bolts that hold sleeve levers (A) and slide sleeve levers (A) out of the way.
5P4209 Gauge Installed
(9) Crossover lever. (10) Dowel pin. (11) 5P4209 Gauge.
8. Loosen the bolts that hold crossover levers (8) and (9) and move crossover lever (8) off dowel pin (10).
Adjustment Of Crossover Levers
(11) 5P4209 Gauge. (12) Shaft. (13) Shaft. (14) 5P4206 Wrench.
9. Put 5P4209 Gauge (11) on shafts (12) and (13), put crossover lever (9) in a position so dowel pin (10) will fit in gauge hole. Hold 5P4209 Gauge (11) down and torque the bolt that holds crossover lever (9) to 2.8 ± 0.2 N·m (24 ± 2 lb in).
10. Check adjustment again with the 5P4209 Gauge (11). Put 5P4209 Gauge (11) on shafts (12 and 13), slide 5P4209 Gauge toward crossover lever (9) to engage dowel pin (10) into hole in 5P4209 Gauge (11).
Tightening Bolt
(8) Crossover lever. (10) Dowel pin. (14) Wrench.
11. If dowel pin (10) must be lifted to go into 5P4209 Gauge, the lever must be adjusted again. If 5P4209 Gauge (11) is lifted, a maximum of 0.20 mm (.008 in) clearance is acceptable under one side of 5P4209 Gauge (11). Use a feeler gauge to check clearance.
12. Slide crossover lever (8) on to dowel pin (10). Torque the bolt that holds crossover lever (8) to 2.8 ± 0.2 N·m (24 ± 2 lb in).
13. Check the adjustment again with the 5P4209 Gauge.